Start of a replacement gasket -
Had what seemed like a good amount of metal to remove from the transmission - might be because some of the studs were just clearing the rear gear.
I kept the two upper 7/16 studs, but replaced the other four 3/8 studs with 3/8-NC to NF studs, shortened them as needed, and then went with 3/8 serrated flange nuts this time - just like the Atlas uses.
One run in, it still seemed tight and didn't leak.
I can't say the same about the rest of the rig..
Pulled out on Friday 9/1 before Labor Day to McKelvey, one of our most difficult natural trails - and one that we rebuilt 5 FS bridges in 10 days, when the FS thought it would take 7-10 years - and yes, the one I broke the rear main leaf on this time last year.
The official ride was Sunday, but I found myself with a few buddies there a day early so.. we'll run it both days!
We did bridge maintenance while we wandered up the trail - that's a requirement with our work-share agreement with the FS. It amounted to shoveling/sweeping debris from the bridges.
On the way back down, I started hearing metal on metal sounds that I found disturbing.
At first, I wondered "dusty shocks?" and then saw the S shaped spring "damaged?" but both were normal (the front springs will sit S shaped against the air bumps when descending - then look flat and normal-ish when you're done)
Eventually I found the cause of the noise after I noticed the transmission and transfer case levers moving more than they should.
No, I didn't forget to tighten the crossmember or transmission mounting bolts.
I broke an RPT engine mount.
On the compression braking side - so every time I would nose over an obstacle and the Scout would go from barely pulling to coasting to aggressive compression braking, I'd hear metal tearing and the levers would flop about.
Solution - pretend I'm wheelin' an Automatic and ride the brakes.
Next problem - good news, I have finally found why the line-lock would slowly release and why I kept finding the brake fluid reservoir a little low - broken brake line behind the shock tower/just rear of the steering box (PITA to get to, of course)
Riding the brakes? Really low on fluid when I got back to camp. I didn't realize the severity until the next day..
So the next day I wound up taking an easier trip, shorter in duration. It was supposed to rain an inch or two over the next day, so it was time to pack up and head home anyways..
Ratchet strap around the air compressor and the frame just in case, and then drive nice and ride the brakes.
The good news is I could still work the skinny pedal all I wanted, I just couldn't do "one pedal" driving like I usually do.
Kids froze at altitude in the backseat - the hail would even bounce inside, though the rain stayed out.
Got it home and have begun the repairs.
I THINK the transmission to transfercase adapter didn't leak.
OTOH, the bellhousing came loose (yikes), the brake line (hard) broke and the reseroir is dry now. The motor mount is shot. I also found I ripped the ladder bar mount off the 14-bolt truss and that has to be addressed (right after I replaced the heim that broke - I guess the new heim is stronger than the brackets)
We'll see what else I find.
I flushed the cooling system and pulled the radiator to get it cleaned - temps were hovering around 220 and climbing to 230-240 at times more than I wanted, and since everythinjg else in my fleet has demanded cooling hoses in the last year, I'm pre-emptively replacing the Scouts' - time for an oil change, too.
WIth the radiator out, I won't have to be as careful replacing the motor mount.
I think I'll finally put a proper hydroboost PS pump in, rather than my extended neck - and getting that out of the way should help me get to the broken brake line to splice it.
New heater hoses while I"m at it, and new ps return hoses because I'm tired of the leak from the current setup.
Fortunately, I have a pair of RPT mounts on the shelf, so I'll be calling Mike to ask about getting the broken one rebuilt (at least one of the rivets failed) - and marven at how I managed to do that on the "coast" side, when - as evidenced by the broken ladder bar again - I do like the skinny pedal.
By then it'll be time to put the hardtop back on..